Micro Lock Mortise Riveted Joint Frame Two Ply Solid Wood Hybrid Engineered Flooring

ABSTRACT

Disclosed is a new type of two-ply solid hybrid wood flooring system that utilizes an improved, more dimensional and stable solid wood backing layer or foundation with continuous solid structural edge beams made out of many small pieces of finger jointed solid wood strips and bonded together in such a way which eliminates waste of raw material, uses less adhesive and yields the maximum structural stability. The present invention combines the dimensional stability characteristics of a traditional perpendicular-grain engineered flooring product with the benefit of the thickness of the traditional solid wood flooring.

CROSS-REFERENCE TO RELATED APPLICATIONS & CONTINUITY DATA

This application claims the benefit of provisional applications No. 61/682,165 and No. 61/693,065, hereby incorporated by reference in their entirety.

BACKGROUND OF THE INVENTION

The traditional solid wood flooring system shown in FIG. 1 consists of a single piece of solid wood machine profiled into a wood plank of various thicknesses and widths. The finished plank usually contains a “tongue” 25 on one side of the board and a “groove” 26 on the opposite side of the board (lengthwise). Making solid flooring generally requires larger sizes raw materials than the final products. This process generates a lot of waste lumber since smaller pieces of strips cannot be used. In addition, solid flooring is generally considered dimensionally unstable.

FIG. 1 is a cross-sectional view of the conventional solid wood flooring. The multi-ply engineered wood flooring system are usually manufactured with multiple layers (as many as eleven) of veneer of various thicknesses and glued together with the grain of the veneers running in perpendicular directions to form a final assembled product. The process of arranging the veneers (23) perpendicular to each other offers this type of flooring more dimensional stability when compared to the solids. However, this process utilizes adhesive chemicals to bond each layer of veneers together under pressure. Each layer of adhesive joint (24) could potentially fail and cause separation between the layers known in the industry as “delaminating” of the product. In addition, the amount and types of adhesive chemicals used to produce this type of engineered flooring could be harmful to human health.

FIG. 2 is a cross-sectional view of the traditional multi-layered engineered wood flooring. There is a need for a flooring product that reinforces sustainable forest product harvest practice methods, utilizes fewer raw materials, uses less adhesive chemical in the manufacturing process as well as possessing performance dimensional stability and aesthetic characteristics of traditional flooring planks. Previous attempts to create such flooring planks have included other 2-ply flooring with grain orientation running perpendicular to each other. These attempts, although similar, generally still do not offer great structural solutions to the common lengthwise “bowing” and widthwise “cupping” of the final finished products.

FIELD OF THE INVENTION

The present invention relates generally to wood flooring systems.

DESCRIPTION OF RELATED ART

The following Patents or Patent Publications are believed to be representative of prior attempts to solve the problem, none of which are herein stated to be prior art:

-   -   U.S. Pat. No. 4,831,806, issued May 23, 1989;     -   U.S. Pat. No. 5,040,582, issued Aug. 20, 1991;     -   U.S. Pat. No. 5,109,898, issued May 5, 1992;     -   U.S. Pat. No. Des. 355, 60 494, issued Feb. 14, 1995;     -   U.S. Pat. No. 5,543,193, issued Aug. 6, 1996;     -   U.S. Pat. No. 5,736,227, issued Apr. 7, 1998;     -   U.S. Pat. No. 5,736, 218, issued Apr. 7, 1998;     -   U.S. Pat. No. 5,738,924, issued Apr. 14, 1998;     -   U.S. Pat. No. 6,162,312, issued Dec. 19, 2000;     -   U.S. Patent Publication No. 2002/0152701,50 published Oct. 24,         2002;     -   U.S. Pat. No. 6,695,944, issued Feb. 24, 2004;     -   U.S. Patent Publication No. 2004/0074190, published Apr. 22,         2004;     -   U.S. Pat. No. 6,878,228, issued Apr. 12, 2005;     -   U.S. Patent Publication No. 2005/0268571, published Dec. 8,         2005;     -   U.S. Pat. No. 7,665,263 B2, issued Feb. 23, 2010;

SUMMARY OF THE INVENTION

An exploded perspective view is shown in FIG. 3, FIG. 6, and FIG. 9. The present two-layer hybrid solid hardwood flooring plank seeks to provide a solution to the problems mentioned in part by laminating a piece of solid conventional hardwood flooring material (known as the wear layer, cover layer, or top layer) (22) to an improved, more dimensional, more stable, and in many embodiments solid wood backing layer or foundation (FIG. 12). The backing layer or foundation may have continuous solid structural edge beams (28) made out of many small pieces of finger jointed solid wood strips (27). These components are bonded together in a way which eliminates waste of raw material, uses less adhesive and yields the maximum structural stability. Furthermore the design may be accomplished with only a single adhesive layer.

The single top wear layer (22) is similar, in some respects, to many conventional engineered flooring products, and it may be composited of any wood species. The top wear layer can be left unfinished or it can be stained and/or finished. Like the conventional solid or engineered flooring, this top wear layer (22) can be smooth, hand scraped, distressed or wire-brushed.

The new and improved single backing layer or foundation (FIG. 12) is made from small pieces of solid finger jointed wood strips (27), again in any wood species. These solid strips of various lengths are finger jointed (29) lengthwise into two longer pieces of solid strips (28) each running in directions parallel under the outer edges of the top wear layer (22).

These two continuous finger jointed long strips of wood containing a tongue (25) and a groove (26) form the plank's edges and also act as structural beams (28) (Edge Beams); Simultaneously the same species of smaller solid strips (27) of equal width and thickness, running in directions perpendicular to the top wear layer and the structural Edge Beams, are fastened together to the two continuous structural Edge Beams (28) by one of the different types of joint methods outlined by (29), (30), and (31).

BRIEF DESCRIPTION OF THE DRAWINGS FIGURES

In general, unless otherwise described in each figure below, element 21 refers to pieces of solid wood flooring, 22 to the top-wear layer, 23 to wood veneers, 24 to adhesive joints, 25 to the tongue, 26 to the groove, 27 to the wood strips, 28 structural edge beams, 29 zigzag finger joints, 30 to the rounded edges tongue & groove connection, and element 31 to the modified V-shape tongue and groove connection.

FIG. 1 illustrates a cross-sectional view of traditional solid wood flooring.

FIG. 2 illustrates a cross-sectional view of traditional multi-layer engineered flooring.

FIG. 3 is an exploded perspective view of the invention, showing the top wear-layer and also the improved Edge Beams backing layer or foundation with Finger-Joints Connection.

FIG. 4 illustrates an isometric drawing of a proposed finished plank manufactured with claims of this present invention.

FIG. 5 illustrates a top view of the present invention. FIG. 5-A is a sectional view of a flooring plank shown in FIG. 4. FIG. 5-B is a detailed view of a flooring plank shown in FIG. 4, showing the continuous structural Edge Beam profiled with the Groove and the zigzag finger joint connections. FIG. 5-C is a detailed view of a flooring plank shown in FIG. 4, showing the continuous structural Edge Beam profiled with the Tongue and the zigzag finger joint.

FIG. 6 is an exploded perspective view of the invention, showing the top wear-layer and also the improved Edge Beams backing layer or foundation with rounded edges T&G connections.

FIG. 7 illustrates an isometric drawing of a proposed finished plank manufactured with claims of this present invention. FIG. 8 illustrates a top view of the present invention. FIG. 8-A is a sectional view of a flooring plank shown in FIG. 7.

FIG. 8-B is a detailed view of a flooring plank shown in FIG. 7, showing the continuous structural Edge Beam profiled with the Groove and the rounded edge T&G connection. FIG. 8-C is a detailed view of a flooring plank shown in FIG. 7, showing the continuous structural Edge Beam profiled with the Tongue and the rounded edge T&G connection.

FIG. 9 is an exploded perspective view of the invention, showing the top wear-layer and also the improved Edge Beams backing layer or foundation with the modified V-shape T&G connections.

FIG. 10 illustrates an isometric drawing of a proposed finished plank manufactured with claims of this present invention.

FIG. 11 illustrates a top view of the present invention. FIG. 11-A is a sectional view of a flooring plank shown in FIG. 10. FIG. 8-B is a detailed view of a flooring plank shown in FIG. 10, showing the continuous structural Edge Beam profiled with the Groove and modified V-shape T&G connections. FIG. 11B is an elevated side view of an edge beam with a modified V-shape.

FIG. 11-C is a detailed view of a flooring plank shown in FIG. 10, showing the continuous structural Edge Beam profiled with the Tongue and modified V-shape T&G connections.

FIG. 12 illustrates a bottom view of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

A preferred embodiment is represented in the exploded perspective view of FIG. 3, showing the top wear layer and also the improved Edge Beams backing layer or foundation with Finger Joints Connection, and in FIG. 6, and FIG. 9. The two-layer, or two ply, hybrid solid hardwood flooring plank seeks to provide a solution to the problems mentioned in the background in part by laminating a piece of solid conventional hardwood flooring material (known as the wear layer, cover layer, or top layer) (22) to an improved, more dimensional, more stable, and more solid structure, of 100% wood (in most embodiments) as a backing layer or foundation (FIG. 12). The backing layer or foundation may be comprised of continuous solid structural edge beams (28) which in turn may be made out of many small pieces of finger jointed solid wood strips (27). These may be bonded together in such a way that eliminates waste of raw material, uses less adhesive and yields the maximum structural stability.

The single top wear layer (22) is similar to most conventional engineered flooring products. It can be composited of any wood species in widths ranging from 3 inches to 12 inches in certain embodiments. Thickness of the wear layers can range from 0.5 millimeters to 6 millimeters thick in certain embodiments. Lengths of the top wear layers are of various sizes from 4 inches up to 12 feet. The top wear layer can be left unfinished or it can be stained and/or finished with any types of wood finishes in any color. Like the conventional solid or engineered flooring, this top wear layer (22) can be smooth, hand scraped, distressed or wire-brushed.

The new and improved single backing layer or foundation layer, shown in FIG. 12, may be comprised of small pieces of solid finger jointed wood strips (27), 6 mm to 15 mm thick in preferred embodiments, in any wood species. These solid strips of various lengths may be finger jointed (29) lengthwise into two longer pieces of solid strips (28) each running in directions parallel under the outer edges of the entire length of the top wear layer (22). These two continuous shaped long strips, or edge beams, of wood with tongue (25) and groove (26) form the plank's edges and also act like structural beams (28) (Edge Beams); Simultaneously the same species of smaller solid strips (27) of equal widths and thickness, running in directions perpendicular to the top wear layer and the structural Edge Beams, are fashioned together to the two continuous structural Edge Beams (28) by one of the different joint methods, (29), (30), (31) as seen in FIG. 5 A-C, FIG. 8 A-C and FIG. 11A-C. a.) Finger joint Connections 29. FIG. 5A-C. b) Rounded edges Tongue and Groove connections 30. FIG. 8A-C. c) Modified V-shape edges Tongue and Groove connections 31. FIG. 11A-C. This improved backing layer with the continuous structure Edge Beams 28 solves the inherent “cupping” and “bowing” problems when compared to other types of two-layer flooring systems.

This unique design utilizes a single adhesive layer a major distinction from other engineered hardwood flooring schemes. As shown in FIG. 6, each interstitial area between the component pieces, the edge beam, the solid wood backing strips, the cover layer, is accessible by a single layer of adhesive. That is, adhesive that is placed in the interstitial area between edge beam and the solid backing strips (at point (29) in FIG. 3, or at point (30) in FIG. 6) is in contact with the any adhesive that may be placed between the backing layer and the cover layer (the area around (27) in FIG. 6). Each interstitial area between component pieces may make connection with another interstitial area and so on such that a single layer of adhesive may connect the system. This has a number of advantages. Delaminating with the current invention requires failure of 100% of the adhesive layers whereas in multiple adhesive layer designs delaminating may occur with as little as 5 or 10% of the adhesive layers failing. Moreover, given that the adhesive is placed within a single layer, either as one continual body of applied adhesive or in a series of dollops, a higher level of quality control is enabled. Consistency in the nature of the adhesive or its application is also much easier to achieve. Further monitoring of the adhesive, its' characteristics or application, is much more easily achieved given the single layer it resides in. In cases where a solid layer of adhesive is applied, as opposed to in spots or dollops, a sensor may even be applied to monitor its qualities. Additionally preformatted and shaped adhesive strips may be deployed within the interstitial area of the flooring system.

In the various embodiments, the hardwood flooring system disclosed herein may be nailed or stapled (or other means known in the art) directly to a wood substrate, it can be glued directly to a concrete substrate and it can also be installed as a floating system on top of any substrate, even over radiant heated floor systems.

The phrase “in one embodiment” is used repeatedly. The phrase generally does not refer to the same embodiment; however, it may. The terms “comprising,” “having” and “including” are synonymous, unless the context dictates otherwise. The following illustrations of various embodiments use particular terms by way of example to describe the various embodiments, but this should be construed to encompass and provide for terms such as “method” and “routine” and the like.

Various aspects of the illustrative embodiments will be described using terms commonly employed by those skilled in the art to convey the substance of their work to others skilled in the art. However, it will be apparent to those skilled in the art that the embodiments described herein may be practiced with only some of the described aspects. For purposes of explanation, specific numbers, materials and configurations are set forth in order to provide a thorough understanding of the illustrative embodiments. However, it will be apparent to one skilled in the art that the embodiments described herein may be practiced without the specific details. In other instances, well-known features are omitted or simplified in order not to obscure the illustrative embodiments.

The characteristics and utilities of the present invention described in this summary and the detailed description below are not all inclusive. Many additional features and advantages will be apparent to one of ordinary skill in the art given the following description. There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood, and in order that the present contribution to the art may be better appreciated.

In this respect, by explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the description. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.

As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the description be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.

Further, the purpose of the foregoing abstract is to enable the U.S. Patent and Trademark Office and the public generally, and especially the scientists, engineers and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application. The abstract is neither intended to define the invention of the application, nor is it intended to be limiting as to the scope of the invention in any way. The characteristics and utilities of the present invention described in this summary and the detailed description below are not all inclusive. Many additional features and advantages will be apparent to one of ordinary skill in the art given the detailed description. 

What is claimed is:
 1. A two ply wood flooring system comprising: a single solid wood foundation, said foundation comprising: solid wood strips finger jointed at two opposite ends, said finger jointed ends connecting to an edge beam; and an edge beam with either a groove or a tongue on a first side, and a either a finger joint or tongue or groove on the opposite side, said finger joint or either tongue or groove on said opposite side connecting to the solid wood strips, and said tongue or groove on the first side connecting to a complimentary tongue or groove on a subsequent edge beam; a cover layer; and a single interstitial adhesive layer securing the edge beam, foundation, and cover layer together.
 2. A two ply solid hardwood flooring system comprising: A top wear layer; A single layer of solid wood foundation frame having: a continuous solid balance beam comprised of smaller pieces of micro lock mortise riveted joint wood strips; and Solid strips of equal widths and thickness running in directions perpendicular to the top wear layer and the balance beams and jointed to the balance beam by a joint; and a single interstitial adhesive layer securing the top wear layer, and the foundation frame.
 3. The system of claim 1 further comprising: a cover layer with a thickness between 0.5 mm and 6 mm, a width between 3 inches and 12 inches, and a length between 4 inches and 12 feet; and a foundation comprised of small pieces of wood strips 2 mm to 20 mm thick.
 4. The system of claim 1, wherein the edge beam is comprised of many small finger jointed solid wood strips.
 5. The system of claim 1, wherein the backing is comprised of waste scraps.
 6. The system of claim 1, wherein delaminating occurs only at failure of 100% of the adhesive layers.
 7. The system of claim 1, wherein a sensor is in contact with the adhesive layer.
 8. The system of claim 1, wherein said system is secured to a wood substrate, a concrete substrate, secured as a floating system above any substrate, or secured above a radiant heated floor system.
 9. The system of claim 1, where the adhesive is comprised of pre-shaped adhesive strips.
 10. The system of claim 2 further comprising: a top wear layer with a thickness between 0.5mm and 6 mm, a width between 3 inches and 12 inches, and a length between 4 inches and 12 feet; and the solid wood strips are comprised of small pieces of wood strips 2 mm to 20 mm thick.
 11. The system of claim 2, wherein the at least one of the balance beam or the solid strips is comprised of waste scraps.
 12. The system of claim 2, wherein delaminating occurs only at failure of 100% of the adhesive layers.
 13. The system of claim 2, wherein a sensor is in contact with the adhesive layer.
 14. The system of claim 2, wherein said system is secured to a wood substrate, a concrete substrate, secured as a floating system above any substrate, or secured above a radiant heated floor system.
 15. The system of claim 2, where the adhesive is comprised of pre-shaped adhesive strips.
 16. A method of wood flooring comprised of securing a two ply wood flooring system with a single layer of adhesive, said two ply wood flooring system comprising: a single solid wood foundation, said foundation comprising: solid wood strips finger jointed at two opposite ends, said finger jointed ends connecting to an edge beam; and an edge beam with either a groove or a tongue on a first side, and a either a finger joint or tongue or groove on the opposite side, said finger joint or either tongue or groove on said opposite side connecting to the solid wood strips, and said tongue or groove on the first side connecting to a complimentary tongue or groove on a subsequent edge beam; and a cover layer.
 17. The method of claim 16 further comprising: a cover layer with a thickness between 0.5 mm and 6 mm, a width between 3 inches and 12 inches, and a length between 4 inches and 12 feet; and a foundation comprised of small pieces of wood strips 2 mm to 20 mm thick.
 18. The method of claim 17, wherein delaminating occurs only at failure of 100% of the adhesive layers.
 19. The method of claim 18, wherein said system is secured to a wood substrate, a concrete substrate, secured as a floating system above any substrate, or secured above a radiant heated floor system.
 20. The method of claim 19, wherein a sensor is in contact with the adhesive layer or the adhesive is comprised of pre-shaped adhesive strips. 